Variable adjustment for precise matching of multiple chamber cavity housings

ABSTRACT

A vertical adjustment assembly is disclosed in order to provide for matching vertical positions of two substrates within separate chambers or cavities of a reaction system for processing of semiconductor substrates. The vertical adjustment assembly, in cooperation with a main lift driver, can provide for a more accurate positioning of the substrates to account for a tolerance stack-up error.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of and claims the right of priority based on U.S. application Ser. No. 15/050,159, entitled “VARIABLE ADJUSTMENT FOR PRECISE MATCHING OF MULTIPLE CHAMBER CAVITY HOUSINGS,” and filed on Feb. 22, 2016, which claims the benefit of U.S. Provisional Application No. 62/234,532, entitled “VARIABLE ADJUSTMENT FOR PRECISE MATCHING OF MULTIPLE CHAMBER CAVITY HOUSINGS,” and filed Sep. 29, 2015, the contents of which are incorporated herein by reference to the extent such contents do not conflict with the present disclosure.

FIELD OF INVENTION

The invention relates to a multiple-chambered reaction system for processing semiconductor substrates. Specifically, the invention relates to a vertical adjustment component of the reaction system to allow for precise matching of wafer processes within different chambers.

BACKGROUND OF THE DISCLOSURE

Assemblies in reaction chambers generally may allow for lateral adjustment and leveling of a wafer lift mechanism. A wafer is disposed on a wafer holder, which may have a heating element. The lateral adjustment allows for horizontal centering of a wafer within the reaction chamber. The lateral adjustment takes place by using independent x-y adjustment block assemblies. For systems with multiple reaction chambers, the lateral adjustment is duplicated for each reaction chamber to center and level the wafer holder.

With respect to leveling of the wafer lift mechanism, leveling ensures that a wafer disposed on the wafer lift mechanism is as flat as possible and parallel to a showerhead disposed above the wafer. The leveling is accomplished through a tripod leveling system. The tripod leveling system includes a three point leveling system with ports to impart pressure onto the wafer to allow for a desired flat position of the wafer. The heater is leveled by the tripod (3-point adjustment) and the tripod is ‘carried’ by the lateral adjusting plate so that centering can be accomplished after leveling. This is due to the fact that leveling will change the position of the heater platen relative to the chamber circular bore. These systems usually have an individual wafer lift mechanisms for each reaction chamber.

Reaction systems exist with multiple chambers to allow for different processing steps. For some of these systems, each chamber may have its own wafer lift mechanism. However, multiple individual wafer lift mechanisms have a disadvantage as each individual lift mechanism incurs significant capital costs. In addition, the cost may rise due to maintenance of each individual wafer lift mechanism. Individual lifts have the following additional disadvantages: (1) More complex software checks are required for motion to occur, slowing throughput; (2) Imprecise motion matching due to manufacturing variances and tolerance stack-ups; (3) Component stack-up due to multiple identical parts requirements and the supporting cables/hoses required for actuation; (4) Multiplied opportunities for sensor failure with a lack of system redundancy (a ‘master’ lift assembly can have multiple redundant sensors if needed and can be easily recovered from a motion sensor error); and (5) Longer system down-time during maintenance due to repetitive setups being required for each chamber and its motion system.

Furthermore, certain applications may require a chamber to be split into separate sections or cavities. While it may be possible to have individual wafer lift mechanisms for each cavity, the cost issues described above and potential spacing issues may not make this feasible. Prior approaches to this issue have utilized a series of tunnels and gas distribution systems to raise separate wafer holders. Other approaches include certain ‘carousel’ systems that have been used in Physical Vapor Deposition (PVD) ‘sputtering’ applications with satisfactory results. These same methods were not as suited for Chemical Vapor Deposition (CVD) and its variant methods including Plasma-enhanced CVD (PECVD) and Atomic Layer Deposition (ALD). These last systems have been the driving force for multiple-wafer processing in matched-chamber environments to regain the throughput lost to PVD systems.

In addition, for multiple cavity systems, another issue with multiple individual wafer lift mechanisms is the reproducibility of reaction conditions. In certain applications, precise chamber matching may be required to allow for process duplication between different cavities. Merely disposing two wafer holders for two cavities on a single wafer lift mechanism may be insufficient because discrepancies with the vertical positions of the two wafer holders may exist as a result of a tolerance stack-up.

A tolerance stack-up is known in the art as an aggregation of mechanical variances within dimensions of various parts within an assembly, resulting in a minimum and maximum value range of variations. An aggregate variation can be great enough to affect the reproducibility of conditions within different cavities. This could potentially lead to defects in manufacturing, as well as decreased chamber life due to deposition material ‘leakage’ into non-process regions of the chamber. As a result, a need exists for a system that allows for the matching of vertical positions in multiple separate cavities of a reaction chamber.

SUMMARY OF THE DISCLOSURE

In accordance with at least one embodiment of the invention, a system is disclosed that comprises: a reference bar that is configured to have a fixed position relative to a horizontal bar; a moveable tie bar configured to move in a vertical position relative to the reference bar; a first movable block coupled to the movable tie bar; a first set of sliding brackets; a first susceptor; a set of rails; and a jacking screw mounted within the reference bar and the movable tie bar, wherein a rotation of the jacking screw causes a vertical movement of the first susceptor.

In accordance with at least one embodiment of the invention, a reaction system is disclosed that comprises: a first chamber cavity; a second chamber cavity; a first susceptor in the first chamber cavity; a second susceptor in the second chamber cavity; a main lift assembly that comprises: a main lift drive; a horizontal bar; a first baseplate; and a second baseplate; and a slave vertical lift assembly comprising: a reference bar; a movable tie bar; a first set of movable blocks; a first set of sliding brackets; a set of rails; and a jacking screw.

In accordance with at least one embodiment of the invention, a method is disclosed that comprises: providing a first chamber cavity for processing a first substrate and a second chamber cavity for processing a second substrate; operating a main lift driver as part of a primary lift assembly to vertically move a first susceptor in the first chamber cavity and to vertically move a second susceptor in the second chamber cavity, the first susceptor configured to hold the first substrate and the second susceptor configured to hold the second substrate; and rotating a jacking screw as part of a secondary lift assembly to match a vertical position of the second substrate with a vertical position of the first substrate.

For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of certain embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

These and other features, aspects, and advantages of the invention disclosed herein are described below with reference to the drawings of certain embodiments, which are intended to illustrate and not to limit the invention.

FIG. 1 illustrates a side view of reaction system according to at least one embodiment of the invention.

FIG. 2 illustrates a side view of a lift mechanism according to at least one embodiment of the invention.

FIG. 3 illustrates an angled view of an adjuster assembly according to at least one embodiment of the invention.

FIG. 4 illustrates a side view of the adjuster assembly according to at least one embodiment of the invention.

FIG. 5 illustrates a bottom view of the adjuster assembly according to at least one embodiment of the invention.

FIG. 6 illustrates a top view of the adjuster assembly according to at least one embodiment of the invention.

FIG. 7 illustrates a back view of the adjuster assembly according to at least one embodiment of the invention.

FIG. 8 illustrates a cross-sectional view of the adjuster assembly according to at least one embodiment of the invention.

FIG. 9 illustrates a side view of the reaction system according to at least one embodiment of the invention.

FIG. 10 illustrates a side view of the reaction system according to at least one embodiment of the invention.

It will be appreciated that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of illustrated embodiments of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Although certain embodiments and examples are disclosed below, it will be understood by those in the art that the invention extends beyond the specifically disclosed embodiments and/or uses of the invention and obvious modifications and equivalents thereof Thus, it is intended that the scope of the invention disclosed should not be limited by the particular disclosed embodiments described below.

FIG. 1 illustrates a reaction system 10 according to at least one embodiment of the invention. The reaction system 10 includes a first reaction cavity 15 and a second reaction cavity 20. The first reaction cavity 15 and the second reaction cavity 20 may comprise of separate chambers or of a single chamber with a divider. The first reaction cavity 15 and the second reaction cavity 20 each comprise an upper portion 25 and a lower portion 30.

Substrate S1, S2 may be loaded onto a susceptor 35 when the susceptor 35 is positioned in the lower portion 30. The susceptor 35 also includes a susceptor heater 40 and a susceptor heater shaft 45. According to another embodiment of the invention, the susceptor 35, heater 40, and the susceptor heater shaft 45 may be of a single piece design and is interchangeable with the multi-piece design illustrated. The susceptor 35 may have alignment tools to allow for accurate positioning of the substrates S1, S2. The substrates S1, S2 may then be processed, when the susceptor 35 is positioned in the upper portion 25. A reaction cavity housing 50 may comprise of several different sections in order to provide a substantially closed environment for the processing of substrates S1, S2.

Movement of the substrates S1, S2 and the susceptor 35 is due in part to a vertical lift assembly 55. The vertical lift assembly 55 comprises a main lift driver 60 configured to move a horizontal bar 65 up and down in a direction 70. The main lift driver 60 may comprise a motor having position feedback via an encoder, hall-effect sensors, or a combination thereof. Attached to the horizontal bar 65 via a set of brackets 75 is a bottom plate 80. The bottom plate 80 is configured to hold a bellows mounting plate 85, upon which a bellows 90 is mounted. The bellows 90 expands and contracts depending upon a position of the susceptor 35 while maintaining isolation of external atmosphere and internal vacuum within the chamber.

FIG. 2 illustrates a vertical lift assembly 100 according to at least one embodiment of the invention. The vertical lift assembly 100 includes a main lift driver 105, which is connected to a horizontal bar 110. The horizontal bar 110 is mounted to a pair of horizontal sliding blocks 115. The horizontal sliding blocks 115 move up and down a pair of guide rails 120. A pair of support bars 125 provides guidance of the horizontal sliding blocks 115 in the up and down movement and serves as a hard-stop to limit vertical upward travel. A plate cap 130 attaches the vertical lift assembly 100 to the bottom of the chamber.

The vertical lift assembly 100 includes a master lift component 150 and a slave lift component 200. Both the master lift component 150 and the slave lift component 200 are connected to the horizontal bar 110. The master lift component 150 comprises a set of brackets 155, a susceptor heater shaft 160, and a rigid-mounted bottom plate 165. On top of the bottom plate 165 is disposed a bellows mounting plate 170. A bellows 175 is connected to the bellows mounting plate 170. At the top of the bellows 175 is a mounting plate 180, which connects to a bottom of a reaction chamber.

Disposed on top of the bellows mounting plate 170 are a set of adjusting micrometers 185. The adjusting micrometers 185 provide for minor height changes of the bellows mounting plate 170 to allow for three-point leveling of the bellows mounting plate 170 and the susceptor mounted to the leveling plate. According to one embodiment of the invention, three adjusting micrometers 185 may be used to accomplish a three-point leveling. In another embodiment of the invention, two adjusting micrometers 185 may be used. Three-point leveling may still be accomplished with two adjusting micrometers 185 if the point without the adjusting micrometer is used as a fixed reference point.

Disposed below the bottom plate 165 are a set of clamps 190. The set of clamps 190 are responsible for maintaining the level adjustment and centering adjustment once it is established. A set of mirrored adjusters 195 are responsible for x-y lateral adjustment of the bellows mounting plate 170. It is preferred that a clamp 190 exists for each mirrored adjuster 195 as well and each fixed point. Within the bellows mounting plate 170, a heater may be installed in order to provide heat to the susceptor through the susceptor heater shaft 160.

The slave lift component 200 shares a number of similarities as the main lift component 150. The slave lift component 200 comprises in part an adjustable bottom plate 210. On top of the bottom plate 210 is disposed a bellows mounting plate 215. A bellows 220 is connected to the bellows mounting plate 215. At the top of the bellows 215 is a mounting plate 225, which connects to a bottom of a reaction chamber.

Disposed on top of the bellows mounting plate 215 are a set of adjusting micrometers 230. The adjusting micrometers 230 provide for minor height changes of the bellows mounting plate 215 to allow for three-point leveling of the bellows mounting plate 215. According to one embodiment of the invention, three adjusting micrometers 230 may be used to accomplish a three-point leveling. In another embodiment of the invention, two adjusting micrometers 230 may be used. Three-point leveling may still be accomplished with two adjusting micrometers 230 if the point without the adjusting micrometer is used as a fixed reference point.

Disposed below the bottom plate 205 are a set of clamps 235. The set of clamps 235 are responsible for maintaining the level adjustment and centering adjustment once it is established. A set of adjusters 240 are responsible for x-y adjustment of the bottom plate 210 and the bellows mounting plate 215. As with clamps 190, it is preferred that a clamp 235 exists for each mirrored adjuster 240 as well and each fixed point.

Within the bellows mounting plate 215, a heater may be installed in order to provide heat to the susceptor through the susceptor heater shaft 205. A set of cooling tubes 245 may be attached to the bellows mounting plate 170 and the bellows mounting plate 215 to prevent overheating of the vacuum-to-atmosphere seal.

The slave lift portion 200 differs from the main lift portion 150 by including additional components. The slave lift portion 200 also comprises a movable bracket 255, a movable tie bar 260, a reference bar 265, and a jacking screw 270. As will be explained in further detail, movement of the jacking screw 270 will cause movement of the moveable tie bar 260 and the movable bracket 255, resulting in a vertical adjustment of the susceptor rod 205 and a substrate on top of a susceptor.

FIG. 3 illustrates an angled view of the slave lift portion 250 according to at least one embodiment of the invention. A set of movable brackets 255 are attached to a bottom plate 210 (not illustrated, but explained with respect to FIG. 2). The set of movable brackets 255 are also connected to a movable tie bar 260. A fixed tie bar 275 and a set of mounting brackets 275′ do not move with respect to the horizontal bar 110 as the fixed tie bar 275 is connected to the horizontal bar. Attached to the fixed tie bar 275 is a set of rails 280. Along these rails, a set of sliding blocks 285 moves up and down. The set of sliding blocks 285 is attached to the set of movable brackets 255 and the movable tie bar 260.

FIG. 4 is a front view of the slave lift portion 250 according to at least one embodiment of the invention. The set of movable brackets 255 is mounted to the set of sliding blocks 285 with a mounting screw 290. Movement of the jacking screw 270 will cause the movable tie bar 260 to move, resulting in causing the set of sliding blocks 285 and the movable brackets 255 to move, while the horizontal bar 110, the fixed tie bar 275 and mounting brackets 275′, and the reference bar 265 stay in place. Screws 295 provide locking force to prevent movement after final adjustment and must be loosened prior to any vertical adjustments of the slave assembly.

FIG. 5 is a top view of the slave lift portion 250 according to at least one embodiment of the invention. The interlocking of the rails 280 and the sliding blocks 285 is such that the movable brackets 255 and the movable tie bar 260 are capable of easily sliding up and down with precise movements.

FIG. 6 is a bottom view of the slave lift portion 250 according to at least one embodiment of the invention. A set of screws 295′ may be used to connect the reference bar 265 to the horizontal bar 110 to provide the thrusting surface required to raise or lower the slave assembly. The screws 295′ may comprise threaded screws, although other fastening devices may be used. As previously mentioned, turning of the jacking screw 270 may allow for movement of the movable tie bar 260 and the sliding blocks 285. This in turn will cause the movable brackets 255 and a substrate located on a susceptor to move upwards or downwards.

FIG. 7 illustrates a back view of the slave lift portion 250 according to at least one embodiment of the invention. The horizontal bar 110 is connected to the fixed tie bar 275, and has an opening to view the movable tie bar 260. Position of the movable tie bar 260 can be viewed through the opening of the horizontal bar 110 depending upon the turning of the jacking screw 270. A U-shaped opening 305 also serves as the upper motion limit of the slave assembly. An upper ‘notched’ cut-out in the horizontal bar 110 serves as a lower hard stop. The combination of these features controls absolute positioning relative to the master susceptor position.

FIG. 8 illustrates a cross sectional view of the slave lift portion 250 from FIG. 4. The jacking screw 270 interfaces with the reference bar 265 and the movable tie bar 260 through several components. The jacking screw 270 is configured to be held in place within the reference bar 265 by a lower threaded nut 310 and an upper threaded nut 315. These nuts 310, 315 set the tension for the thrust bearing and are locked into place to prevent going out of adjustment. An upper thrust bearing race 320, a lower thrust bearing race 325, and a thrust bearing roller and cage 330 allow for force to be applied relative to capture faces in the reference bar 265. A helicoil thread insert 340 may be configured to prevent galling of the threads of the screw under load. Depending upon the direction the force is applied, the z-axis adjuster moves up or down along a direction 335. For example, force exerted against the lower thrust race 325 is accomplished by turning the jacking screw 270 counter clockwise, which in-turn causes the movable tie bar 260 to travel upward. Once the position is set, locking screws 295 prevent undesired vertical movement of the slave assembly relative to the master, ensuring consistent and synchronous vertical position of both susceptors and substrates.

Likewise an opposite motion will result in the movement of the movable tie bar 260 along an opposite direction 325. The rotation of the jacking screw 270 may take place via an operator or potentially a programmable robot or potentially a miniature pneumatic linear or rotary actuator.

FIG. 9 illustrates a reaction system 400 in accordance with at least one embodiment of the invention. FIG. 9 is similar to the reaction system illustrated in FIG. 1, but shows a susceptor and substrate in a different position. The reaction system 400 comprises a first chamber cavity 405 and a second chamber cavity 410, in which substrates can be processed. A reaction cavity housing 415 may comprise of several different sections in order to provide a substantially closed environment for the processing of the substrates.

Within the first chamber cavity 405, a first substrate S1 is brought upward into a processing position by a first susceptor 420. The first susceptor 420 may also include a first susceptor heater 425. The processing position is defined in part by a first baseplate 430 that juts from the reaction cavity housing 415. The first substrate S1 being in an up position is evidenced by a contraction of a first bellow 435. The first bellow 435 is mounted upon a first bellow mounting plate 440, which is disposed on a first lower plate 445. The first lower plate 445 is mounted on a horizontal bar 450. Movement of the horizontal bar 450 is driven by a main lift driver 455.

Within the second chamber cavity 410, a second substrate S2 is brought upward into a processing position by a second susceptor 460. The second susceptor 460 may also include a second susceptor heater 465. The processing position within the second chamber cavity 410 is defined in part by a second baseplate 470 that juts from the reaction cavity housing 415. The second substrate S2 being in an up position is evidenced by a contraction of a second bellow 475. The second bellow 475 is mounted upon a second bellow mounting plate 480, which is disposed on a second lower plate 485. The second lower plate 485 is mounted on the horizontal bar 450. On the side of the horizontal bar 450 associated with the second susceptor 460 is also installed a vertical lift assembly 500, similar to the embodiments discussed above. The vertical lift assembly includes in part a jacking screw 505.

As shown in FIG. 9, there is a small discrepancy 510 in the vertical positions of the first substrate S1 and the second substrate S2. The discrepancy 510 can result as a result of a tolerance stack-up error. An aggregate variation within components of the reaction system 400 can be great enough to affect the reproducibility of conditions within the first reaction cavity 405 and the second reaction cavity 410. As previously stated, inability to reproduce conditions accurately could potentially lead to defects in manufacturing, as well as decreased chamber life due to deposition material ‘leakage’ into non-process regions of the chamber.

FIG. 10 illustrates a reaction system 400 in accordance with at least one embodiment of the invention. The small discrepancy 510 shown in FIG. 9 can be eliminated by turning the jacking screw 505. Turning the jacking screw 505 in a direction 515 will move the second susceptor 460 and the second substrate S2 upward in a direction 520. As a result, the vertical positions of the first substrate S1 and the second substrate S2 will be matched, allowing a reproduction of conditions within the first chamber cavity 405 and the second chamber cavity 410.

The particular implementations shown and described are illustrative of the invention and its best mode and are not intended to otherwise limit the scope of the aspects and implementations in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or physical couplings between the various elements. Many alternative or additional functional relationship or physical connections may be present in the practical system, and/or may be absent in some embodiments.

It is to be understood that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific routines or methods described herein may represent one or more of any number of processing strategies. Thus, the various acts illustrated may be performed in the sequence illustrated, in other sequences, or omitted in some cases.

The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various processes, systems, and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof. 

What is claimed is:
 1. A reaction system for processing multiple semiconductor substrates, comprising: a first chamber cavity for processing a first substrate; a second chamber cavity for processing a second substrate; a first susceptor in the first chamber cavity, the first susceptor configured to hold the first substrate; a second susceptor in the second chamber cavity, the second susceptor configured to hold the second substrate; a main lift assembly configured to move the first susceptor and the second susceptor in a vertical direction, the main lift assembly comprising: a main lift drive; a horizontal bar configured to be moved by the main lift drive; a first baseplate attached to a first side of the horizontal bar, the first baseplate configured to guide the first susceptor; and a second baseplate attached to a second side of the horizontal bar, the second baseplate configured to guide the second susceptor; and a slave vertical lift assembly assigned to the second chamber cavity, the slave vertical lift assembly comprising: a reference bar configured to have a fixed position relative to a main lift bar; a movable tie bar configured to move in a vertical position relative to the reference bar; a first set of movable blocks coupled to the movable tie bar; a first set of sliding brackets mounted to the first set of movable blocks, the first set of sliding brackets configured to hold the second baseplate and a first bellows mounting plate; a set of rails for guiding movement of the first set of movable blocks; and a jacking screw mounted within the reference bar and the movable tie bar, wherein a rotation of the jacking screw causes a vertical movement of the second susceptor.
 2. The system of claim 1, wherein the jacking screw raises or lowers the second susceptor to match a position of the second substrate in the second chamber cavity with a position of the first substrate in the first chamber cavity.
 3. The system of claim 1, further comprising a lower threaded nut, a thrust bearing race, an upper threaded nut, and a helicoil insert in contact with the jacking screw.
 4. The system of claim 3, wherein the thrust bearing race comprises a lower thrust bearing race, a thrust bearing roller and cage, and an upper thrust bearing race.
 5. The system of claim 1, wherein the rotation of the jacking screw is performed by a human operator or a programmable robot.
 6. The system of claim 1, further comprising a set of micrometers to provide a tripod leveling to the first bellows mounting plate. 